Negative Electrode Active Material for Lithium Ion Rechargeable Battery and Negative Electrode Using the Same

ABSTRACT

There is provided a negative electrode for a lithium ion secondary battery high in discharge capacity per unit volume, small in capacity loss at the time of initial charge/discharge, and excellent in rapid charge/discharge characteristics. 
     Natural graphite, rendered spherical in shape, is mixed with carbon black, and pitch is added to a mixture thus formed to be thermally kneaded before baked at a temperature in a range of 900 to 1500° C., thereby obtaining graphite particles (A), each being substantially spherical in shape, and having fine protrusions on the surface thereof. Since the graphite particles (A) have the fine protrusions on the surface thereof, a multitude of electrically conducting networks are built in a complex way within an electrode, the graphite particles (A) can serve as a negative electrode material excellent in rapid charge/discharge characteristics, and power characteristics. The graphite particles (A) further baked at 3000° C. to be graphitized are turned into graphite particles (B), each having similarly fine protrusions on the surface thereof. Further, carbonaceous particles (C) are also obtained by baking a mixture of pitch and carbon black in the range of 900 to 1500° C. By mixing those particles together as appropriate, it is possible to increase electrode density, thereby obtaining a lithium ion secondary battery having less deterioration in discharge capacity holding ratio, and excellent cycle characteristics. In accordance with Raman spectroscopic analysis using argon laser Raman scattering light, there exists a G-band composite peak comprising peaks in the vicinity of 1600 cm −1 , and 1580 cm −1 , respectively, and at least one peak in the vicinity of D-band at 1380 cm −1 , an interlayer distance of the lattice plane d 002 , obtained by wide-range X-ray diffraction, being in the range of 0.335 to 0.337 nm.

FIELD OF THE INVENTION

The present invention relates to a negative electrode active material for a lithium ion rechargeable battery for use in a notebook computer, a cellular phone, and so forth, and in particular, to a negative electrode having high capacity, less capacity loss, and excellent in charge and discharge repeatability (cycle characteristics), and a negative electrode active material. Further, the present invention relates to a negative electrode active material for use in a negative electrode having high power, and high output, such as a carbon negative electrode for use in a medium/large sized lithium ion rechargeable battery for use in an electric bicycle (E-bike), a hybrid electric vehicle (HEV), and so forth, a method of preparing thereof, and a negative electrode using the negative electrode active material.

BACKGROUND OF THE INVENTION

The lithium ion rechargeable battery has been in widespread use as a small and light-weight rechargeable battery having high capacity and high voltage, suitable for use in a portable equipment such as a cellular phone, a video camera, and so forth. Further, the lithium ion rechargeable battery having high-output has lately come into widespread use as a power supply for an electric power tool requiring large power.

As there has been seen no sign of slowdown in the trend for the portable equipment towards further miniaturization, higher performance, and higher function, so it is expected to minimize and to make it lighter, and higher capacity for the lithium ion rechargeable battery.

While attempts have been made to improve performance of each component of the lithium ion rechargeable battery and materials thereof. Among other things, the effort is focused on improving the density and the capacity of a negative electrode material which is considered to be a limit factor a performance of the lithium ion rechargeable battery, and that spheroidizing of a graphite particle for improving the performance is proposed in Patent No. Jp 2983003.

Further, in Patent Document 5 (JP 7-249411 A), it has been disclosed that for the purpose of obtaining a negative electrode material for a lithium ion secondary battery having large discharge capacity, pretreatment is applied to a carbonizable material at a pressure not lower than 10 kgf/cm², and a heat treatment temperature not higher than 600° C. in an inert atmosphere to be subsequently subjected to carbonization treatment at a temperature in a range of about 500 to 3300° C. More specifically, it has been described that carbonization is conducted in a range of 1500 to 3300° C. if the carbonizable material is a material easy to carbonize, and in a range of 500 to 1500° C. if the carbonizable material is a material hard to carbonize.

In Patent Document 6 (JP 11-73963 A), there has been described a negative electrode composite material for a lithium ion secondary battery, wherein a binder is carbonized into a matrix carbon, that is produced by a process comprising the steps of forming slurry comprised of filler graphite, a carbonizable binder, and a solvent for dissolving the binder into spheres by use of a spray—dry method, obtaining agglomerates by drying the spheres, and subsequently rendering the binder infusible or heating the agglomerates in a range of 900 to 1400° C. in an inert atmosphere without rendering the binder infusible

[Patent Document 1] JP 2983003 [Patent Document 2] JP 3588354 [Patent Document 3] JP 3716830 [Patent Document 4] JP 3716818 [Patent Document 5] JP7-249411 A [Patent Document 6] JP11-73963 A DISCLOSURE OF THE INVENTION

It is widely known that the discharge capacity per unit weight of the carbon-base negative electrode material has substantially reached to a theoretical value thereof, and in order to enhance a battery capacity, it is required that the negative electrode material should be packed into a battery as much as possible, that is, a negative electrode density must be higher than 1.7 g/cm³, preferably higher than 1.8 g/cm³. Furthermore, an inexpensive negative electrode of higher productivity, and capable of maintaining high capacity is required.

Meanwhile, from the viewpoint of environmental issues, an electric vehicle, particularly, the hybrid electric vehicle (HEV) using a nickel-hydrogen battery in combination with a gasoline engine has been developed, and an attention is focused on a lithium ion battery higher in energy density, and generating a high voltage as a power supply source for use in an HEV of the next generation.

Higher input/output characteristics as compared with those used for a small-sized lithium ion battery used for conventional portable equipment are required of the lithium ion battery used for the HEV, however, the lithium ion battery used for the HEV is just at the beginning of development.

In order to manufacture a low cost battery, it is necessary to use an inexpensive material having a long life performance, and the same can be said of a negative electrode material.

In order to obtain a high-capacity battery, a vein and flake natural graphite used for a negative electrode is preferable as it is inexpensive, and its supply is stable. However, the vein and flake natural graphite has charge/discharge efficiency less than 90%, and particles thereof, when applied to a copper foil to serve as an electrode, are oriented in one direction on a plane, consequently a cycle characteristics, and a performance at low temperature is not satisfactory.

Further, as the electrode density is increased, the particles thereof stick to one another, thereby clogging up a flow path formed between the particles through which an electrolyte is to flow, and which leads to problems such as deterioration in battery characteristics, and so forth. Therefore, it is not practical to use the vein and flake natural graphite in a natural state.

In order to solve this problem, there have been developed graphite particles produced by reforming vein and flake natural graphite particles to spherical shape, and applying coating to the surface thereof, however, the product cost is largely dependent on a coating process. For example, in the case of a method of depositing pyrocarbon on the surface of each of graphite particles by CVD process, it requires expensive facilities, and highly-developed operating techniques, and furthermore, since there exists a problem with productivity, it is difficult to supply products at low cost.

A method of coating the surface with resin and pitch is carried out by use of, for example, a heating kneader, or mechanical treatment (mechanochemical process). With the use of the heating kneader, production is feasible at a relatively low cost, but the mechanochemical process is inferior in terms of productivity to a method using the heating kneader.

A coating formed on the surface of graphite particles produced by any of those methods is smooth.

Since the graphite particles produced by a conventional method is substantially spherical in shape, and has a smooth surface, if an electrode is made up by use of the graphite particles, and charge/discharge are repeated with the electrode, there will occur a decrease in the number of contact points between the particles of a negative electrode material, due to repetition of expansion/contraction of the negative electrode material, thereby causing an electrically conductive network inside the electrode to collapse, so that a problem is prone to occur to the cycle characteristics.

The present invention proposes graphite particles to serve as a negative electrode material for a lithium ion rechargeable battery high in discharge capacity per unit volume, small in capacity loss at the time of initial charge/discharge, and excellent in load characteristics at the time of quick charge/discharge, and so forth, and a negative electrode using the same.

SUMMARY OF THE INVENTION

The inventors have continued researches on the graphite particles produced by rendering the vein and flake natural graphite spherical in shape, and applying coating to the surface thereof, and as a result, have found out that graphite particles having the following structure are suitable for use as a negative electrode material for a lithium ion secondary battery.

The graphite particles include graphite particles (A), each being substantially spherical in shape, and having fine protrusions on the surface thereof, obtained by impregnating, and coating a matrix of vein and flake natural graphite, rendered spherical in shape, with a mixture of pitch and carbon black, to be subsequently baked at a temperature in a range of 900 to 1500° C., and graphite particles (B), each being substantially spherical in shape, and having fine protrusions on the surface thereof, obtained by further graphitizing the graphite particles (A) at a high temperature.

Further, a mixture of the graphite particles (A) and the graphite particles (B) can be similarly used as the negative electrode material.

Further, graphite particles (A), each particle being substantially spherical in shape, and having fine protrusions on the surface thereof, obtained by impregnating, and coating a matrix of vein and flake natural graphite, rendered spherical in shape, with a mixture of pitch and carbon black, to be subsequently baked in a range of 900 to 1500° C., before pulverization and screening, mixed with carbonaceous particles (C) obtained by baking the mixture of pitch and carbon black in the range of 900 to 1500° C. before sizing is also useful as the negative electrode active material for the lithium ion secondary battery.

The negative electrode active materials have a G-band composite peak comprising peaks in the vicinity of 1600 cm⁻¹, and 1580 cm⁻¹, respectively, and at least one peak in the vicinity of a D-band at 1380 cm⁻¹, in Raman spectroscopic analysis using argon laser Raman scattering light at a wavelength of 514.5 nm, an interlayer distance of a lattice plane, d₀₀₂, obtained by wide-range X-ray diffraction, being in a range of 0.335 to 0.337 nm, so that the negative electrode active material is a powdery carbon material of a multi-layer structure, serving as an excellent negative electrode active material for a lithium ion secondary battery, having both high-output characteristics and high energy density.

Natural graphite rendered spherical in shape, for use in the graphite particles (A), and the graphite particles (B), respectively, having average particle diameter in a range of on the order of 3 to 25 μm, can be put to use. The natural graphite spherical in shape, not more than 3 μm in average particle diameter, is not preferable not only because of a drawback in respect of cost as it is difficult to render the natural graphite spherical in shape, thereby causing a decrease in productivity, but also because of difficulty in producing a homogeneous complex with particle size distribution under control since a particle size is small when the natural graphite is turned into the complex by impregnating, and coating the same with pitch and carbon black.

With the natural graphite spherical in shape, exceeding 25 μm in average particle diameter, a proportion of particles existing therein, exceeding 70 μm in maximum particle diameter, becomes high due to particle size distribution, and a problem will arise upon coating in the case of an electrode small in thickness on the order of 40 μm as generally considered, so that the particles are preferably controlled to about 25 μm in average particle diameter at most, and to the order of 75 μm at the maximum.

As for the graphite particle (A), graphite particles (A1, A2, A3, . . . ) obtained by impregnating, and coating not less than two kinds of matrices, an average particle diameter of a spherical natural graphite particle making up each of the matrices being varied, with a mixture of pitch and carbon black, respectively, to be baked at a temperature in a range of 900 to 1500° C. before pulverization and screening, the graphite particles (A1, A2, A3, . . . ) mixed with each other, and the graphite particles (A1, A2, A3, . . . ) mixed with the carbonaceous particles (C1, C2, . . . ), at an optional mixing ratio according to a purpose such as powder physical properties, and so forth, may be used as a negative electrode active material for a lithium ion secondary battery.

The graphite particles (A) are obtained by applying impregnation·mixing·thermal kneading to natural graphite reduced spherical in shape, using carbon black and pitch, thereby coating the surface of work in process with the carbon black and the pitch, to be baked at a high temperature for carbonization, followed by sizing through pulverization and screening. The natural graphite spherical in shape, carbon black, and pitch may be mixed with each other to be subsequently thermally kneaded, or the carbon black may be added while the natural graphite spherical in shape is thermally kneaded with the pitch. Herein, thermal kneading refers to an operation whereby process materials are charged into a kneader and so on, and are kneaded with each other while heating is applied thereto.

The graphite particles (A) have numerous fine protrusions composed of a composite material of carbon originating from the carbon black, and carbon originating the pitch, formed on the surface thereof. Accordingly, the graphite particle (A) has a large surface area as compared with a particle having a smooth surface, and there are many contact points formed between the particles, so that a multitude of electrically conducting networks are built in a complex way within an electrode, thereby causing electrical resistance of the negative electrode to be lowered. Thus, the graphite particles (A) can serve as a negative electrode material excellent in rapid charge/discharge characteristics, and power characteristics.

An amount of the carbon black is preferably in a range of 2 to 50 parts by weight against 100 parts by weight of the natural graphite. If the amount of the carbon black corresponds to less than 2% against an amount of the natural graphite, the fine protrusions will be less in amount, so that satisfactory results cannot be obtained. If the amount of the carbon black exceeds 50%, a specific surface area will become excessively large, which is not preferable because of excessively large capacity loss.

Heating is carried out at a temperature in a range of 900 to 1500° C. in a non-oxidizing atmosphere. Heating at a temperature below 900° C. is not preferable because functional groups remain on respective surfaces of the particles to react with lithium ions, resulting in an increase of capacity loss, and occurrence of an infection point of a discharge curve, in the vicinity of 1V.

Graphitization treatment generally refers to heat treatment applied at a temperature not lower than 2000° C. Accordingly, in the case of producing the graphite particles (A), heat treatment in a range of 900 to 2000° C. is applied. However, since 2000° C. around which heat treatment is applied is a treatment temperature at which the discharge capacity will become nearly the lowest, the heat treatment is applied in a range of 900° C. to not higher 1500° C. in practice, preferably in a range of 900° C. to not higher 1200° C.

The carbonaceous particles (C) are carbonaceous porous powders obtained by baking, and pulverizing a thermally kneaded mixture of pitch and carbon black before sizing by use of an air sifter, and screening.

More specifically, carbon black and pitch are charged into a kneader, and so on, thermal kneading is applied to a mixture of the carbon black and the pitch while heating is applied thereto, and after the pitch is sufficiently wetted against the carbon black and a composite material thereof is formed, the composite material is taken out of the kneader, and so on, to be transferred to a vessel made of metal, ceramics, or graphite, whereupon baking is carried out in a non-oxidizing atmosphere. Generally by taking out the composite material while being mixed/stirred inside the kneader, and so on, the same is discharged in the form of agglomerates ranging from several mm to several cm in size, so that the agglomerates, as they are, can be charged into the vessel to be then baked. The agglomerates may be molded into an optional shape easy to handle, as necessary, with the use of a molding machine, to be subsequently baked.

As is the same case with the graphite particles (A), baking is conducted in a range of 900 to 1500° C. The reason why the baking is conducted in such a temperature range as described is the same as the reason in the case of the graphite particles (A).

Mechanical pulverization is conducted after the baking such that a particle size suitable to the initial purpose can be obtained. Sizing with the use of an air sifter or a vibrating screen as necessary is carried out in order to adjust particle size distribution.

Further, a mixing ratio of the pitch to the carbon black is determined by taking into consideration intended properties of the carbonaceous particles (C) to be produced, and an oil absorption quantity of the carbon black, but one measure of the mixing ratio is the pitch in a range of on the order of 25 to 250 parts by weight against 100 parts by weight of the carbon black. If the mixing ratio of the pitch is less than 25 parts by weight against 100 parts by weight of the carbon black, an amount of the pitch is insufficient, resulting in formation of an unsatisfactory composite with the carbon black. If the mixing ratio of the pitch is in excess of 250 parts by weight, the pitch will be excessive in ratio against the carbon black, so that the composite will be too close in properties to a baked product composed solely of the pitch, which represents deviation from the purpose of the invention.

There are known several kinds of carbon blacks such as furnace black, acetylene black, ketene black, lamp black, and so forth, differing in respect of raw material, production method, and so forth. Those carbon blacks are further classified into complex brands according to magnitude of a structure (DBP oil absorption quantity: expressed by magnitude of dibutyl phthalate oil absorption) formed by linkage of a plurality of primary particles several tens of nm in size, size of a specific surface area, measured by absorption/desorption of nitrogen gas, difference in pore diameter distribution, and difference in other characteristics.

There is no particular limitation to the brand of carbon black in actual use, however, it is necessary to select a brand, and determine a blending amount of the brand in consideration of various physical properties as intended.

An amount of carbon black is set to a range of 2 to 50 parts by weight against 100 parts by weight of natural graphite. If the carbon black is less than 2% against the natural graphite, fine protrusions become small in amount, so that satisfactory results cannot be obtained. If the carbon black exceeds 50%, a specific surface area will become excessively large, which is not preferable because a large capacity loss occurs.

For the pitch, use can be made of a common binder pitch, and an impregnation pitch. Use may be made of either a coal based pitch, or a petroleum based pitch, but a softening point is in a range of 70 to 250° C., preferably in a range of 80 to 150° C., and more preferably in a range of 80 to about 120° C. If the softening point is excessively low, this will not be preferable because of inconvenience in handling, and an increase in cost due to a low carbonaceous residue ratio. Conversely, if the softening point is excessively high, such pitch will be unsuitable for executing processing in a common heating kneader, so that use of special facilities will be unavoidable. Thus, the pitch having the excessively high softening point is unsuitable for mass production. Further, the excessively high softening point is not desirable in terms of cost because a pitch price will increase.

A heat treatment temperature is in a range of 900° C. to 3200° C. A heat treatment temperature below 900° C. is not preferable because the functional groups remain on the respective surfaces of the particles and will react with lithium ions, so that there occur an increase in capacity loss, and there exists an infection point of the discharge curve in the vicinity of 1V.

In case of obtaining the graphite particles (B), a baking temperature in the graphitization should be not lower than 2000° C. at the lowest, however, in order to enhance discharge capacity·charge/discharge efficiency, graphitization is preferably carried out at a temperature as high as possible. The baking temperature for obtaining the graphite particles (B), not lower than 2600° C. is required at the lowest, preferably not lower than 2800° C., and more preferably not lower than 3000° C. If the baking temperature exceeds 3400° C., the graphite will undergo sublimation, and therefore, heat treatment at 3200° C. is a practical limitation.

In the case of making up an electrode by use of the graphite particles according to the invention, if the electrode is for use in a notebook PC, mobile phone, and so forth, a conventional particle size in general use, that is, the average particle diameter D₅₀ in a range of on the order of 8 to 25 μm is preferable. Meanwhile, in the case of an intermediate sized/large sized lithium ion secondary battery for use in an electric bicycle (E-bike), a hybrid electric vehicle (HEV), and so forth, the graphite particles are coated to a relatively small thickness in order to ensure electrical conductivity of an electrode, and to cause the electrode to exhibit output characteristics, so that the average particle diameter D₅₀ is in a range of on the order of 3 to 15 μm, more preferably in a range of on the order of 5 to 13 μm. Further, there is the need for limiting the maximum particle diameter to a size less than a thickness of the electrode in any application. Furthermore, means for adding a supplementary electrical conductive agent as necessary may be selected as appropriate in addition to the above. If the average particle diameter D₅₀ is not more than 3 μm, this will cause difficulty in pulverization, so that there arise problems such as an increase in production cost, increase in specific surface area, considerable deterioration in handling characteristics, and so forth.

Further, if the average particle diameter D₅₀ is not less than 15 μm, it is neither possible to apply the graphite particles to the electrode to have a small thickness, nor to obtain sufficient contact between the particles, thereby causing electrical resistance to increase, and output characteristics to deteriorate, so that high-output characteristics cannot be obtained.

It is appropriate to set the maximum particle diameter to not more than 55 μm. Because an electrode in application for high output is formed such that a thickness thereof after pressed is in a range of about 40 to 50 μm, if the maximum particle diameter is 55 μm or more, it is not possible to obtain a smooth and uniform coating.

Further, if an electrode is formed to have a large thickness exceeding 50 μm under prevailing circumstances, the average particle diameter, and/or the maximum particle diameter of an electrode active material can be increased according to the thickness of the electrode, however, it is preferable that the average particle diameter D₅₀ is kept to 25 μm at most, and the maximum particle diameter is kept to on the order of 75 μm.

In general, in the case of a graphite negative electrode material being in use, material of series containing no propylene carbonate (hereinafter referred to as PC) is used for an electrolyte. PC is prone to cause decomposition reaction on the surface of graphite, thereby causing an increase in internal pressure of a battery, and generating a large quantity of decomposition products (SEI coating) on the negative electrode material, resulting in deterioration of battery characteristics, so that PC is not preferable.

For effecting normal charge/discharge even in an electrolyte with PC added thereto, it is necessary to check the decomposition reaction of PC, occurring on the negative electrode material. That is, it is necessary to render the surface of the particle low in crystallinity. With a negative electrode active material composed singly of the graphite particles (A) obtained by baking a thermally kneaded mixture of the spherical natural graphite particles, carbon black, and pitch at a temperature in the range of 900 to 1500°, or a negative electrode active material composed of a mixture of the graphite particles (A), and the graphite particles (B) obtained by further baking the graphite particles (A) at a high temperature to be then graphitized, formed at a mixing ratio of the graphite particles (A)=50 to 100%, the graphite particles (B)=0 to 50%, and (A)+(B)=100%, charge/discharge is possible without capacity loss even in the electrolyte with PC (PC concentration in the electrolyte is not more than 33%) added thereto.

However, if a proportion of the graphite particles (B) exceeds 50%, a decomposition quantity of PC will increase, thereby causing initial charge/discharge efficiency to deteriorate, and therefore, the graphite particles (B) in excess of 50% in proportion is not preferable. Furthermore, since the quantity of the SEI coating as formed will increase, electrical resistance will increase, thereby deteriorating high-rate characteristics, and cycle characteristics.

Since the graphite particles (A) have an amorphous surface, and the particle surface is hard, it is difficult to increase the electrode density to not less than 1.7 g/cm³. In order to increase the electrode density to not less than 1.7 g/cm³, there is the need for rendering the particles susceptible to being crushed. On the other hand, in the case of the graphite particles (B) obtained by graphitization at the high temperature, the electrode density can be easily increased to not less than 1.7 g/cm³. However, since the graphite particle (B) is susceptible to being crushed as compared with the graphite particle (A), flow paths of the electrolyte tend to be blocked up when the electrode density is increased.

If a mixing ratio of the graphite particles (A)=0 to 30%, the graphite particles (B)=70 to 100%, and (A)+(B)=100% is adopted, there will be no capacity loss even at the electrode density not less than 1.7 g/cm³, that is, it becomes possible to enhance discharge capacity per unit volume (mAh/cm³). In this case, in consideration of reaction of the particles with PC, it is necessary to use PC such that PC concentration in the electrolyte is not more than 10%.

If the mixing ratio of the graphite particles (A) exceeds 30%, it becomes difficult to increase the electrode density to not less than 1.7 g/cm³.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1(A), 1(B) each shows electron micrographs of graphite particles according to the invention;

FIG. 2 is a graph showing cycle characteristics;

FIG. 3 is a graph showing cycle characteristics of a high-density electrode;

FIG. 4 is a graph showing constant-current charge capacities according to Examples and Comparative Examples, respectively;

FIG. 5 is a graph showing constant-current charge capacity holding ratios according to Examples and Comparative Examples, respectively;

FIG. 6 is a graph showing discharge capacities according to Examples and Comparative Examples, respectively;

FIG. 7 is a graph showing discharge capacity holding ratios according to Examples and Comparative Examples, respectively;

FIG. 8 is a graph showing Raman spectrum of the graphite particles (A) according to the invention, obtained by Raman spectroscopy;

FIG. 9 is a graph showing the results of fitting of the Raman spectrum of the graphite particles (A) according to the invention;

FIG. 10 is a graph showing Raman spectrum of a negative electrode active material according to Example of the invention; and

FIG. 11 is a graph showing the results of fitting of the Raman spectrum of the negative electrode active material according to an Example of the invention.

PREFERRED EMBODIMENT OF THE INVENTION Tests on Higher Density and Higher Capacity Example 1

A mixture was formed by mixing 100 parts by weight of natural graphite rendered spherical in shape with 20 parts by weight of acetylene black (particle diameter 62 nm, a specific surface area by BET method 68 m²/g) and further, 18 parts by weight of isotropic pitch was added to the mixture to be subsequently thermally kneaded with the use of a heating kneader at 150° C. for one hour. The mixture was baked at 1000° C. in a non-oxidizing atmosphere before pulverization, and sizing, having thereby obtained graphite particles (A) substantially spherical in shape, each particle having fine protrusions on the surface thereof. In FIG. 1 (A), there are shown electron micrographs of the graphite particles (A).

The graphite particles (A) were further baked at 3000° C., having thereby obtained graphite particles (B). It was found that an average particle diameter D₅₀=11.97 μm, the maximum particle diameter D_(top)=38.9 μm, an interlayer distance of the lattice plane, d₀₀₂=3.357 Å, as measured by X-ray diffraction according to Gakushin-method for X-ray diffraction of carbon, and a specific surface area by BET method, SSA=3.39 m²/g. In FIG. 1(B), there are shown electron micrographs of the graphite particles (B).

By mixing 2 parts by weight of SBR (styrene-butadiene rubber) and 2 parts by weight of CMC (carboxymethylcellulose) with 100 parts by weight of the graphite particles (B), a mixture was formed, slurry of the mixture was prepared with the use of distilled water as solvent, and the slurry was then applied to a copper foil with the use of a doctor blade to be dried at 120° C., and pressed at a pressure of 1 t/cm², whereupon electrode density was found at 1.70 g/cm³.

When the electrode density was 1.80 g/cm³, time(s) required for complete permeation of an electrolyte of 1M LiPF₆/EC:MEC (1:1), 2 μl in volume, was 1520 seconds.

Example 2

The graphite particles (B) according to Example 1, and the graphite particles (A) as a precursor of the graphite particles (B) were mixed with each other at a blending ratio of A/B=30/70(by weight), thereby having produced a negative electrode active material. It was found that an average particle diameter D₅₀=11.96 μm, the maximum particle diameter D_(top)=38.9 μm, the interlayer distance of the lattice plane, d₀₀₂=3.357 Å, as measured by X-ray diffraction according to Gakushin-method for X-ray diffraction of carbon, and the specific surface area by BET method, SSA=3.47 m²/g.

The negative electrode active material was mixed with a binder, and a mixture was subsequently applied to a copper foil, and dried before being pressed at a pressure of 1 t/cm², whereupon electrode density was found at 1.65 g/cm³.

When the electrode density was 1.80 g/cm³, time(s) required for complete permeation of an electrolyte of 1M LiPF₆/EC:MEC (1:1), 2 μl in volume, was 1170 seconds.

Comparative Example 1

A mixture was formed by adding 18 parts by weight of isotropic pitch to 100 parts by weight of natural graphite rendered spherical in shape to be subsequently thermally kneaded with the use of a heating kneader at 150° C. for one hour. The mixture was baked at 1000° C. in a non-oxidizing atmosphere, having thereby obtained graphite particles.

As for a particle size, an average particle diameter D₅₀=14.0 μm, the maximum particle diameter D_(top)=38.9 μm, and the interlayer distance of the lattice plane, d₀₀₂=3.357 Å, as measured by X-ray diffraction according to Gakushin-method for X-ray diffraction of carbon, while the specific surface area by BET method, SSA=1.25 m²/g.

The graphite particles obtained were used for a negative electrode active material, and was mixed with a binder, and a mixture was subsequently applied to a copper foil, and dried before being pressed at a pressure of 1 t/cm², whereupon electrode density was found at 1.46 g/cm³.

When the electrode density was 1.80 g/cm³, time(s) required for complete permeation of an electrolyte of 1M LiPF₆/EC:MEC (1:1), 2 μl in volume, was 1520 seconds.

Comparative Example 2

The graphite particles according to Comparative Example 1 were further baked at 3000° C. to be thereby graphitized. It was found that a particle size was an average particle diameter D₅₀=13.1 μm, D_(top)=38.9 μm, and the interlayer distance of the lattice plane, d₀₀₂=3.356 Å as measured by X-ray diffraction according to Gakushin-method for X-ray diffraction of carbon, while the specific surface area by BET method, SSA=1.37 m²/g.

A negative electrode active material composed of the graphite particles obtained was mixed with a binder, and a mixture was subsequently applied to a copper foil, and dried before being pressed at a pressure of 1 t/cm², whereupon electrode density was found at 1.76 g/cm³.

When the electrode density was at 1.80 g/cm³, time(s) required for complete permeation of an electrolyte of 1M LiPF₆/EC:MEC (1:1), 2 μl in volume, was 2990 seconds. Those results are shown in Table 1

TABLE 1 comparative comparative example 1 example 2 example 1 example 2 “a” 1.70 1.65 1.46 1.76 “b” 1520 1170 1520 2990 Remarks: “a” = electrode density (g/cm³) after pressed at a contact pressure of 1 t/cm², “b” = electrolyte permeation time (sec) at the time when electrode density is 1.80 g/cm³

As shown in Table 1, with the graphite particles according to Example 1, and the graphite particles according to Example 2, respectively, the electrode density (g/cm³) after pressed was found higher, press-workability was found excellent, electrolyte permeation time was short, and permeability was found excellent.

With Example 1, and Example 2, the electrolyte permeation time was 1520 seconds, and 1170 seconds, respectively, in the case where the electrode density was 1.80 g/cm³, indicating that the electrolyte permeation time was the same as the conventional one or shorter than that, so that those graphite particles are high in density, and electrolyte permeability, being excellent as the negative electrode active material. With Comparative Example 2, the reason why the electrolyte permeation time was as long as 2990 seconds is that the graphite particles were crushed by pressing, thereby blocking up flow paths of an electrolyte. In contrast, with Example 1, although the graphite particle (B) was susceptible to being crushed due to pressing, flow paths were maintained owing to presence of the protrusions on the surface of each of the particles, so that the electrolyte permeation time was found short.

In Table 2, there are shown discharge capacity and discharge efficiency when the electrode density is varied to 1.6, 1.7, and 1.8 (g/cm³), respectively, when the graphite particles according to Example 1, and the graphite particles according to Example 2, respectively, were used for the negative electrode active material. Charge/discharge was conducted with a double-pole coin cell using Li metal as a counter electrode, and 1M LiP₆/EC:MEC (1:1) as an electrolyte. Constant-current charge was first carried out at a current value 0.5 mA/cm² to be switched to constant-voltage charge upon a voltage value reaching 0.01V, and the constant-voltage charge was continued until the current value came down to 0.01 mA/cm². After completion of the constant-voltage charge, the constant-current discharge was carried out at the current value 0.5 mA/cm², completing the discharge upon the voltage value reaching 1.5V.

It is evident from Table 2 that the graphite particles according to the invention are excellent because the discharge capacity and the discharge efficiency did not deteriorate even if the electrode density was increased.

TABLE 2 electrode density (g/cm³) 1.6 1.7 1.8 example 1 352/91.8 351/90.4 350/90.6 example 2 353/91.3 352/90.3 351/90.5 Remarks: discharge capacity (mAh/g)/discharge efficiency (%)

Examples Concerning PC Resistance Characteristics Example 3

The graphite particles (A), that is, the precursor of the graphite particles (B) according to Example 1, were used as they were. The particle size of the graphite particles (A) was an average particle diameter D₅₀=11.9 μm, the maximum particle diameter D_(top)=38.9 μm, and it was found that the interlayer distance of the lattice plane, was d₀₀₂=3.357 Å, as obtained by X-ray diffraction according to Gakushin-method for X-ray diffraction of carbon, and the specific surface area by BET method, was SSA=3.65 m²/g.

Slurry was prepared by mixing 5 parts by weight of PVdF {poly(vinylidiene fluoride)} or 2 parts by weight of SBR and CMC, respectively, with 100 parts by weight of the graphite particles (A), and the slurry was applied to a copper foil by use a doctor blade to be dried at 120° C. before applying roll-pressing thereto, having thereby formed an electrode. The electrode after pressed had a thickness 80 μm, and had the electrode density at 1.6 g/cm³. A double-pole coin cell using Li metal as a counter electrode, and 1M LiP₆/EC:MEC (1:2) and 1M LiP₆/PC:EC:MEC (1:3:6), as an electrolyte, was manufactured, whereupon charge/discharge tests were conducted. The constant-current charge was carried out at the current value 0.5 mA/cm² to be switched to the constant-voltage charge upon the voltage value reaching 0.01V, and the constant-voltage charge was continued until the current value came down to 0.01 mA/cm². After completion of the constant-voltage charge, the constant-current discharge was carried out at the current value 0.5 mA/cm², completing the discharge upon the voltage value reaching 1.5V. Discharge capacity is as shown in Table 3.

Difference in discharge capacity and discharge efficiency between the electrolyte containing PC, and the electrolyte containing no PC is hardly observed, and charge/discharge can be implemented without causing capacity loss.

TABLE 3 discharge discharge capacity efficiency binder electrolyte (mAh/g) (%) PVdF EC:MEC(1:2) 348 90 PC:EC:MEC(1:3:6) 352 90 SMR/CMC EC:MEC(1:2) 351 92 PC:EC:MEC(1:3:6) 351 92

Example 4

The graphite particles (B) according to Example 1 were mixed with the graphite particles (A) according to Example 3 at a blending ratio of A/B=50/50 (by weight), having thereby producing a negative electrode active material. It was found that an average particle diameter D₅₀=11.95 μm, the maximum particle diameter D_(top)=38.9 μm, and the interlayer distance of the lattice plane, was d₀₀₂=3.357 Å, as measured by X-ray diffraction according to Gakushin-method for X-ray diffraction of carbon, and the specific surface area by BET method was SSA=3.52 m²/g.

When a negative electrode had a thickness 80 μm, and electrode density at 1.80 g/cm³, and during a time period of change in voltage value from 0.01V to 1.5V, discharge capacity and discharge efficiency were 351 mAh/g, and 90.5%, respectively, if 1M LiP₆/EC:MEC (1:2) was used as an electrolyte, while the discharge capacity and the discharge efficiency were 351 mAh/g, and 90.0%, respectively, if 1M LiP₆/PC:EC:MEC (1:3:6) was used as the electrolyte.

In the case of the electrolyte with PC added thereto, the discharge capacity, and the discharge efficiency were found excellent without undergoing deterioration.

Example and Comparative Example, Concerning Rapid Charge/Discharge Example 5

Example 5 is similar to Example 3 except that furnace black (particle diameter: 68 nm, a specific surface area by the BET method: 23 m²/g) was used in place of the acetylene black.

The particle size of the graphite particles (A) was an average particle diameter D₅₀=13.5 μm, the maximum particle diameter D_(top)=38.9 μm, and it was found that the interlayer distance of the lattice plane, was d₀₀₂=3.357 Å, as measured by Gakushin-method for X-ray diffraction of carbon, and the specific surface area by BET method was SSA=2.18 m²/g.

In the case where the thickness of the negative electrode after pressed was 40 μm, and the electrode density of the negative electrode was 1.40 g/cm³ with reference to Example 3, Example 5, and Comparative Example 1, respectively, discharge capacity, and discharge efficiency, from 0.01V to 1.5V, and the capacities including discharge capacity at a current value 10 C up to 1.0V after adjustment to a discharge depth (DOD)=50%, and discharge capacity when the constant-current discharge was carried out at a current value 2 C up to 0V are as shown in Table 4. With Example 3, and Example 5, respectively, the discharge capacity, and the discharge efficiency were found enhanced as compared with Comparative Example 1. Furthermore, as the capacity at the time of rapid charge/discharge was found high, it can be said that high-power characteristics are excellent.

TABLE 4 from DOD = 50% 10C 2C discharge discharge discharge capacity efficiency capacity capacity (mAh/g) (%) (mAh/g) (mAh/g) Example 3 380 87.0 137 22.5 Example 5 369 85.5 141 55.7 Comparative 353 85.1 81 16.2 Example 1

Tests on Cycle Characteristics

A cycle test was conducted on an electrode having electrode density at 1.6 g/cm³, using the graphite particles according to Example 1, Example 3, and Comparative Example 1, respectively. The constant-current charge was carried out at the current value 0.5 C to be switched to the constant-voltage charge upon the voltage value reaching 0.01V, continuing the charge until the current value came down to 0.01 mA/cm². After completion of the charge, the constant-current discharge was carried out at the current value 0.5 C, completing the discharge upon the voltage value reaching 1.5V. The cycle tests were conducted by repeating the charge/discharge described as above. Results of the tests are shown in FIG. 2. In contrast to an electrode using the graphite particles according to Comparative Example 1, each particle having no fine protrusions on the surface thereof, wherein as cycle numbers increase, so a discharge capacity holding ratio is seen deteriorated, the graphite particles. according to the invention, used for the negative electrode active material, had a small decrease in the discharge capacity, indicating excellent cycle characteristics.

Further, in FIG. 3, there is shown cycle characteristics of Example 1 for a high-density application type when the electrode density was 1.8 g/cm³. In the figure, there is shown cycle characteristics identical to that in the case of the electrode density being 1.6 g/cm³, indicating excellent cycle characteristics without causing deterioration in cycle characteristics, due to an increase in the electrode density.

The graphite particles (A) and the carbonaceous particles (C) were produced, respectively, by varying conditions as follows, and tests were run on performance of various mixtures thereof, as a negative electrode material for a lithium ion secondary battery. Mixing ratios in the following description are in terms of percent by weight.

Now, there are shown hereinafter examples of the negative electrode active material for the lithium ion secondary battery, composed of the graphite particles (A1, A2, A3, . . . ) obtained by impregnating, and coating not less than two kinds of matrices, an average particle diameter of a spherical natural graphite particle making up each of the matrices being varied, with a mixture of pitch and carbon black, respectively, to be baked at a temperature in a range of 900 to 1500° C. before pulverization and screening, the graphite particles (A1, A2, A3, . . . ) mixed with each other, the graphite particles (A1, A2, A3, . . . ) mixed with the carbonaceous particles (C1, C2, . . . ) at an optional mixing ratio according to the purpose such as powder physical properties, and so forth.

The Graphite Particles (A)

A1: A mixture was formed by mixing 100 parts by weight of natural graphite reduced to a spherical shape, having an average particle diameter D₅₀ 11 μm, and the maximum particle diameter D_(top)=28 μm, with 20 parts by weight of a commercially available furnace black having an arithmetic average particle diameter 46 nm, DBP oil absorption quantity 106 ml/100 g, a BET specific surface area 38 m²/g, and iodine absorption 40 mg/g, and further, 15 parts by weight of binder pitch having a softening point at 110° C. was added to the mixture to be subsequently thermally kneaded at 150° C. for one hour with the use of a heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through a screen with 38 μm openings, having thereby obtained the graphite particles (A1) substantially spherical in shape. A2: By mixing 100 parts by weight of natural graphite reduced to a spherical shape, having an average particle diameter D₅₀ 11 μm, and the maximum particle diameter D_(top)=28 μm, with 20 parts by weight of a commercially available acetylene black having an arithmetic average particle diameter 35 nm, DBP oil absorption quantity 160 ml/100 g, a BET specific surface area 69 m²/g, and iodine absorption 93 mg/g, a mixture was formed, and further, 18 parts by weight of binder pitch having a softening point at 110° C. was added to the mixture to be subsequently thermally kneaded at 150° C. for one hour with the use of a heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the graphite particles (A2) substantially spherical in shape. A3: By mixing 100 parts by weight of natural graphite reduced to a spherical shape, having an average particle diameter D₅₀ 23 μm, and the maximum particle diameter D_(top)=65 μm, with 20 parts by weight of a commercially available acetylene black having an arithmetic average particle diameter 35 nm, DBP oil absorption quantity 160 ml/100 g, the BET specific surface area 69 m²/g, and the iodine absorption 93 mg/g, a mixture was formed, and further, 16 parts by weight of binder pitch having a softening point at 110° C. was added to the mixture to be subsequently thermally kneaded at 150° C. for one hour with the use of the heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the graphite particles (A3) substantially spherical in shape. A4: By mixing 100 parts by weight of natural graphite reduced to a spherical shape, having an average particle diameter D₅₀ 23 μm, and the maximum particle diameter D_(top)=65 μm, with 20 parts by weight of the commercially available furnace black having an arithmetic average particle diameter 46 nm, DBP oil absorption quantity 106 ml/100 g, the BET specific surface area 38 m²/g, and the iodine absorption 40 mg/g, a mixture was formed, and further, 16 parts by weight of binder pitch having a softening point at 110° C. was added to the mixture to be subsequently thermally kneaded at 150° C. for one hour with the use of the heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the graphite particles (A4) substantially spherical in shape. A5: By mixing 100 parts by weight of natural graphite reduced to a spherical shape, having an average particle diameter D₅₀=5 μm, and the maximum particle diameter D_(top)=17 μm, with 20 parts by weight of a commercially available furnace black having an arithmetic average particle diameter 46 nm, DBP oil absorption quantity 106 ml/100 g, the BET specific surface area 38 m²/g, and the iodine absorption 40 mg/g, a mixture was formed, and further, 20 parts by weight of binder pitch having a softening point at 110° C. was added to the mixture to be subsequently thermally kneaded at 150° C. for one hour with the use of the heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the graphite particles (A5) substantially spherical in shape. A6: By mixing 100 parts by weight of natural graphite reduced to a spherical shape, having an average particle diameter D₅₀=5 μm, and the maximum particle diameter D_(top)=17 μm, with 10 parts by weight of a commercially available furnace black having an arithmetic average particle diameter 24 nm, DBP oil absorption quantity 115 ml/100 g, the BET specific surface area 117 m²/g, and the iodine absorption 80 mg/g, a mixture was formed, and further, 20 parts by weight of binder pitch having a softening point at 110° C. was added to the mixture to be subsequently thermally kneaded at 150° C. for one hour with the use of the heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the graphite particles (A6) substantially spherical in shape.

The Carbonaceous Particles (C)

C1: By adding 50 parts by weight of a binder pitch having a softening point at 110° C. to 100 parts by weight of a commercially available furnace black having an arithmetic average particle diameter 24 nm, the DBP oil absorption quantity 115 ml/100 g, BET specific surface area 117 m²/g, and iodine absorption 80 mg/g, a mixture was formed, and the mixture was subsequently thermally kneaded at 150° C. for one hour with the use of the heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the carbonaceous particles (C1). C2: By adding 50 parts by weight of a binder pitch having the softening point at 110° C. to 100 parts by weight of a commercially available furnace black having an arithmetic average particle diameter 23 nm, the DBP oil absorption quantity 108 ml/100 g, BET specific surface area 123 m²/g, and iodine absorption 115 mg/g, a mixture was formed, and the mixture was subsequently thermally kneaded at 150° C. for one hour with the use of the heating kneader. Then, the mixture was baked at 1000° C. in a non-oxidizing atmosphere to be pulverized and sifted through the screen with 38 μm openings, having thereby obtained the carbonaceous particles (C2).

Example 6

A mixture of the graphite particles (A) and the carbonaceous particles (C) was produced by mixing at a blending ratio of A2:C1=90:10. Table 5 shows various physical properties of the mixture as produced.

Example 7

The graphite particles (A) were mixed with the carbonaceous particles (C) at a blending ratio of A2:C1=85:15. Table 5 shows various physical properties of a mixture as produced.

Example 8

The graphite particles (A) were mixed with the carbonaceous particles (C) at a blending ratio of A1:C1=90:10. Table 5 shows various physical properties of a mixture as produced.

Example 9

The graphite particles (A) were mixed with the carbonaceous particles (C) at a blending ratio of A1:C2=94:6. Table 5 shows various physical properties of a mixture as produced.

Example 10

The graphite particles (A) were mixed with the carbonaceous particles (C) at a blending ratio of A1:A5:C1=85:10:5. Table 5 shows various physical properties of a mixture as produced.

Example 11

The graphite particles (A) were mixed with the carbonaceous particles (C) at a blending ratio of A2:A3:A6:C1=70:10:10:10. Table 5 shows various physical properties of a mixture as produced.

Comparative Example 3

A mixture was formed by adding 18 parts by weight of isotropic pitch to 100 parts by weight of natural graphite reduced spherical in shape to be subsequently thermally kneaded with the use of a Warner kneader at 150° C. for one hour. The mixture was baked at 3000° C. in a non-oxidizing atmosphere to be subsequently graphitized. Various physical properties of a product thus obtained are shown in Table 5.

Comparative Example 4

Heat treatment at 500° C. was applied to coal pitch (optical isotropy) containing 10% of QI content, and having a softening point at 110° C. under nitrogen gas bubbling (21 l/min·kg), having thereby obtained a carbon precursor of 30% optical anisotropy according to observation with a polarization microscope. The carbon precursor contained 0.3% of volatile matter. A softening point thereof was measured by Metlar method, but could not be measured indicating that measurement of the softening point was not possible. The carbon precursor was pulverized, and sized to be reduced to have an average particle diameter D₅₀=8 μm to be subsequently baked at 1300° C. in a non-oxidizing atmosphere. Various physical properties of a product thus obtained are shown in Table 5.

TABLE 5 particle size (μm) d₀₀₂ L_(c002) D₁₀ D₅₀ D₉₀ D_(top) (nm) (nm) a b c d Example 6 7.79 13.15 23.85 46.08 0.336 >100 0.93 6.25 352 84 Example 7 7.71 13.21 24.12 46.08 0.336 >100 0.91 5.91 347 84 Example 8 7.41 12.56 22.63 38.86 0.336 >100 1.00 6.39 358 86 Example 9 7.61 12.70 22.13 38.86 0.336 >100 0.95 6.37 356 87 Example 10 6.34 11.64 21.15 38.86 0.336 >100 0.89 6.48 360 86 Example 11 5.84 11.34 23.91 54.64 0.336 >100 0.90 7.42 354 85 Comparative 10.47 17.08 28.47 46.08 0.336 >100 1.00 1.08 360 89 Example 3 Comparative 3.98 10.94 23.73 46.08 0.349 1.8 1.16 1.51 236 83 Example 4 Remarks: a = bulk density (g/cm³), b = specific surface area (m²/g), c = discharge capacity (mAh/g), and d = discharge efficiency (%)

As shown in Table 5, with any of Examples 6 to 11, the interlayer distance of the lattice plane d₀₀₂ was found to fall in the range of 0.335 to 0.337 nm, and the discharge capacity indicated high capacity in a range of 350 to 360 mAh/g.

Meanwhile, with Comparative Example 3, the interlayer distance of the lattice plane d₀₀₂ was found the same as that for any of Examples 6 to 11, and the discharge capacity was found equivalent to that for any of Examples 6 to 11 although the specific surface area was as small as one fifth of that for any of Examples 6 to 11. With Comparative Example 4, the interlayer distance of d₀₀₂ was found large as compared with Examples 6 to 11, respectively, exceeding 0.337 nm, and the discharge capacity indicated a fairly low value.

It has been confirmed that if paste obtained by adding an organic binder, and a dispersing medium to the negative electrode active material for the lithium ion secondary battery, according to any of Examples 6 to 11, before kneading, is applied to a current collector made of metal to be dried and pressed, thereby fabricating a negative electrode having a coating with a thickness in a range of 30 to 100 μm, and electrode density in a range of 0.9 to 1.8 g/cm³, this will enable rapid charge/discharge, and render high-output characteristics excellent.

In FIGS. 4, 5, 6, and 7, there are shown constant-current charge capacity, a constant-current charge capacity holding ratio, discharge capacity, and a discharge capacity holding ratio, respectively, in the case of varying a charge rate, and a discharge rate, respectively, when use was made of, for example, a negative electrode having a coating thickness in a range of 30 to 50 μm, and electrode density in a range of 1.1 to 1.5 g/cm³, fabricated by applying paste obtained by adding an organic binder and a dispersing medium to negative electrode active materials for a lithium ion secondary battery, according to Examples and Comparative Examples, respectively, before kneading, to a current collector made of metal to be further dried and pressed.

With both Example 6, and Example 7, deterioration in the constant-current charge capacity, constant-current charge capacity holding ratio, discharge capacity, and discharge capacity holding ratio, respectively, was found less as compared with Comparative Examples 3, 4, respectively, in the case of charge/discharge carried out by increasing the charge rate, and the discharge rate, respectively, indicating that Example 6, and Example 7 are excellent in both rapid-charge performance, and rapid-discharge performance.

By use of the laser Raman spectroscopic analysis, and wide-range X-ray diffraction, measurement was taken on physical properties of the negative electrode active material according to the invention. Measurement conditions in detail are shown hereunder.

For the laser Raman spectroscopic analysis, use was made of Ramanor T-64000 model manufactured by Jobin Yvon/Atago Bussan. Analysis conditions in detail are as follows.

Measurement mode: macro-Raman Measurement disposition: 60° Beam diameter: 100 μm Light source: Ar+laser/514. 5 nm Laser power: 10 mW Diffraction grating: Single 600 gr/mm

Dispersion: Single 21 A/mm Slit: 100 μm Detector: CCD/Jobin Yvon 1024×256

Measurement was taken by optionally selecting 3 points from the surface of a specimen.

In the laser Raman spectroscopic analysis of the negative electrode active material for the lithium ion secondary battery, according to the invention, there is observed Raman spectrum considered as a mixed system of not less than two kinds. Accordingly, it is difficult to numerically express the Raman spectrum by an R-value, that is, a ratio (I_(D)/I_(G)) of intensity I_(D) of the D-band (a peak appearing in the vicinity of 1360 cm⁻¹) to intensity I_(G) of the G-band (a peak appearing in the vicinity of 1600 cm⁻¹), or by a value corresponding to a half-value width of the G-band. That is, it can be said that it is meaningless to work out the R-value for convenience's sake by directly reading intensity of respective peaks from peaks as obtained.

For interpretation of the spectrum, separation of components of each band was carried out by fitting. As the spectrum was obtained as the mixed system comprised mainly of the low crystalline and the high crystalline, the G-band was separated between a low crystalline component in the vicinity of 1600 cm⁻¹, and a high crystalline component in the vicinity of 1580 cm⁻¹. On the other hand, in the case of the D-band in the vicinity of 1360 cm⁻¹, well-defined difference in peak position, and half-value width was not observed, so that the separation of the components was difficult to execute.

Since the D-band cannot be divided, it becomes practically impossible to handle the R-value. However, it is possible to work out area percentage of each of the components as a parameter for numerically expressing a shape of the spectrum, as a contribution ratio.

The fitting was carried out on the basis of Lorentz function for three components, and a background component of one component. With Raman band having the peak in the vicinity of 1600 cm⁻¹, a peak position was fixed to 1600 cm⁻¹. The background component is presumed to stem from amorphous carbon, and since a shape of the spectrum thereof is unknown, the fitting was carried out through approximation by Gaussian function.

The base line was linearly approximated at 600 to 2000 cm⁻¹. There are shown hereinafter description of respective parameters directly read from Raman spectrum as observed, or after the fitting:

Directly Reading

R: I_(D)/I_(G)

I_(D): intensity of D-band (in the vicinity of 1360 cm⁻¹) I_(G): intensity of G-band (in the vicinity of 1600 cm⁻¹) After the fitting

R: I₁₃₆₀/I₁₆₀₀

I₁₃₆₀: intensity of D-band (in the vicinity of 1360 cm⁻¹) I₁₃₈₀: intensity of Raman band in the vicinity of 1380 cm⁻¹ (amorphous component) I₁₅₈₀: intensity of G-band (in the vicinity of 1580 cm⁻¹) (high crystalline component) I₁₆₀₀: intensity of G′-band (in the vicinity of 1600 cm⁻¹) (low crystalline component) Δν₁₅₈₀: band width of G-band (in the vicinity of 1580 cm⁻¹) Δν₁₆₀₀: band width of G′-band (in the vicinity of 1600 cm⁻¹) contribution ratio: area intensity of each Raman band/the sum of area intensities of all the bands A₁₃₆₀: area intensity of D-band (in the vicinity of 1360 cm⁻¹) A₁₃₈₀: area intensity of Raman band in the vicinity of 1380 cm⁻¹ (amorphous component) A₁₅₈₀: area intensity of G-band (in the vicinity of 1580 cm⁻¹) (high crystalline component) A₁₆₀₀: are intensity of G′-band (in the vicinity of 1600 cm⁻¹) (low crystalline component)

A measurement depth of Raman spectrum is dependent on absorption coefficient of a specimen. In the case of a black material such as carbon, a measurement depth decreases. In the case of graphite, a measurement depth estimated from absorption coefficient by excitation at 514.5 nm is presumably about 15 nm. In the case of an amorphous carbon, a measurement depth generally increases presumably to dozens of nm.

X-ray wide-range diffraction was carried out on the basis of the Gakushin-method for specifying a method for conducting structural analysis on size of crystallite of a synthetic carbon material with metallic silicon as the internal standard, mesh size, and so forth, using an X-ray diffraction apparatus RINT-Ultima III manufactured by Rigaku Co., Ltd.

By charging 60±0.1 g of a specimen into a graduated cylinder of 100 ml, setting the graduated cylinder to an in-house tap density measuring instrument with a cam provided therein, and tapping the specimen 700 times at a stroke of 10 mm, having thereby worked out a tap density from a volume of the specimen thus obtained.

A specific surface area was measured on the basis of a pore volume, pore diameter, absorption/desorption of nitrogen gas, and as a measuring instrument, use was made of an automatic specific surface area/pore diameter distribution measuring instrument Tristar 3000 manufactured by Micromeritics Corp.

The specific surface area was found by the BET multiple-point method whereby an absorption gas quantity obtained from an absorption isotherm is evaluated as a monomolecular layer to thereby calculate a specific surface area.

P/V(P ₀ −P)=(1/VmC)+{(C−1)/VmC(P/P ₀)}  (1)

S=kVm  (2)

where P₀: saturation vapor pressure P: absorption equilibrium pressure V: absorption quantity at an absorption equilibrium pressure P Vm: absorption quantity of a monomolecular layer C: parameter concerning absorption heat S: specific surface area k: nitrogen monomolecular occupancy area 0.162 nm²

The total pore volume was found from an equilibrium relative pressure (P/P₀) obtained from the absorption isotherm=a saturated absorption gas quantity in the vicinity of 0.99.

A volume of a micro-pore not more than 2 nm was found by the t-plot method whereby an absorption quantity is plotted against a thickness t of a nitrogen gas absorption film.

An absorption film thickness in a range of 0.35 to 0.50 nm was found according to Harkins & Jura expression:

t=[13.99/{0.034−log(P/P ₀)}]⁰⁵  (3)

where P₀: saturation vapor pressure, P: absorption equilibrium pressure.

An oil absorption quantity was measured according to JIS K6217, with the use of an absorption-quantity measuring instrument S-410 model manufactured by Asahi Soken Co. Ltd., using linseed oil.

Measurements on an average particle diameter, and particle size distribution, respectively, were conducted with the use of LMS-30 System developed by Seishin Enterprise Co., Ltd, whereby measurement was executed with water serving as a dispersing medium, kept in an ultrasonic dispersion state by use of a trace of surfactant as a dispersant.

For electrochemical charge/discharge tests, a water-base slurry was prepared by mixing 2 parts by weight of SBR and CMC, as a binder, respectively, with 100 parts by weight of the negative electrode active material, and the slurry was applied to a copper foil to have a thickness 80 μm by use a doctor blade to be dried at 120° C. before applying roll-pressing thereto, having thereby punched work in process into an electrode of φ 12. The electrode after pressed was 40 μm in thickness

Li metal was used for a counter electrode against the electrode, a group of the electrodes opposed each other, with a separator interposed therebetween, was formed, subsequently an electrolyte of 1M LiPF₆/EC:MEC (1:2) was added thereto, having thereby fabricated a coin cell, and the coin cell was subjected to the charge/discharge tests.

Charging/discharging were executed under conditions that the constant-current charge was first carried out at a current value 0.5 mA/cm² to be switched to the constant-voltage charge upon a voltage value reaching 0.01V, and the constant-voltage charge was continued until the current value came down to 0.01 mA/cm². After completion of the constant-voltage charge, the constant-current discharge was carried out at the current value 0.5 mA/cm², completing the discharge upon the voltage value reaching 1.5V.

In measurement on rapid charge, and rapid discharge, the discharge depth (DOD) was first at 100% for discharge capacity from 0 to 1V while DOD prior to the measurement was adjusted to 50%. The rapid charge, and the rapid discharge were carried out at the constant current by varying the C rate from the state of DOD=50%. Further, as for a capacity holding ratio, capacity at 0.2 C was defined as 100%, having thereby found a variation ratio when the C rate was increased.

In FIG. 8, there is shown the Raman spectrum of the negative electrode active material according to Example 1, as an example of Raman spectrum.

As shown in FIG. 8, a shoulder is observed near a peak in the vicinity of 1600 cm⁻¹.

FIG. 9 shows the results of fitting of the Raman spectrum shown in FIG. 8. The peak in the vicinity of 1600 cm⁻¹ could be separated between the low crystalline component in the vicinity of 1600 cm⁻¹, and the high crystalline component in the vicinity of 1580 cm⁻¹.

Raman spectrum shown in FIG. 10 indicates the Raman spectrum of the negative electrode active material, that is, the mixture of the graphite particles (A) and the carbonaceous particles (C), according to Example 10.

As shown in FIG. 10, a shoulder is observed near a peak in the vicinity of 1600 cm⁻¹.

With reference to Raman band in FIG. 10, the peak intensity, and the area intensity are shown in Tables 6, and 7, respectively.

TABLE 6 Raman Band-peak intensity, and band width I₁₆₀₀ Δν₁₆₀₀ I₁₅₈₀ Δν₁₅₈₀ I₁₃₈₀ I₁₃₆₀ cps cm⁻¹ cps cm⁻¹ cps cps I_(1360/)I₁₅₈₀ I_(1360/)I₁₅₈₀ 9.24 78.66 4.75 25.45 6.34 5.05 1.05 0.55

TABLE 7 Raman Band-area intensity contribution ratio A₁₆₀₀ A₁₅₈₀ A₁₃₈₀ A₁₃₆₀ (area percentage) cps cps cps cps A₁₆₀₀ A₁₅₈₀ A₁₃₈₀ A₁₃₆₀ 1091 187.3 2431 611.8 25% 4% 56% 14%

As described in the foregoing, the carbon material of the multi-layer structure, according to the present invention, having the G-band composite peak comprising the peaks in the vicinity of 1600 cm⁻¹, and 1580 cm⁻¹, respectively, and at least one peak in the vicinity of the D-band at 1380 cm⁻¹, in Raman spectroscopic analysis using the argon laser Raman scattering light at the wavelength of 514.5 nm, wherein the interlayer distance of the lattice plane d₀₀₂, obtained by wide-range X-ray diffraction, is in the range of 0.335 to 0.337 nm, is a negative electrode active material for a lithium ion secondary battery, having both high capacity characteristics and high-output characteristics.

INDUSTRIAL APPLICABILITY

Numerous fine protrusions are present on the surface of each of the graphite particles according to the present invention, as shown in FIG. 1. By virtue of the fine protrusions present on the surface of each of the graphite particles, the number of contact points between the particles will increase as compared with the case of a particle having a smooth surface, so that numerous electrically conducting networks are built in a complex way within an electrode, and electrical resistance of the negative electrode is lowered, thereby rendering the graphite particles according to the present invention suitable for use as a negative electrode material excellent in rapid charge/discharge characteristics, and power characteristics.

Since the negative electrode material is not only excellent in the rapid charge/discharge characteristics, and power characteristics, but also is high in density, capacity, and efficiency, the negative electrode material can be put to widespread use ranging from use in a small sized battery of a mobile phone, a notebook PC, and so forth to use in a large sized battery in a large equipment such as a hybrid electric vehicle (HEV).

The graphite particles (A), the surface of the particle being amorphous pitch and carbon black, singly, or the mixture of the graphite particles (A), and the graphite particles (B) obtained by further graphitizing the graphite particles (A) can be used even in an electrolyte with propylene carbonate (PC) added thereto.

Further, if a mixing ratio of the graphite particles (A)=0 to 30%, the graphite particles (B)=70 to 100%, and (A)+(B)=100% (by weight) is adopted, there is observed no deterioration in characteristics even at the electrode density increased to not less than 1.7 g/cm³, so that it becomes possible to enhance the discharge capacity per unit volume.

Further, a mixture of the graphite particles (A), each substantially spherical in shape, and having fine protrusions on the surface thereof, obtained by impregnating, and coating a matrix of natural graphite, rendered spherical in shape, with a mixture of pitch and carbon black, to be subsequently baked in the range of 900 to 1500° C., and the carbonaceous particles (C) obtained by baking the mixture of pitch and carbon black in the range of 900 to 1500° C. before pulverization and sizing, the mixture has the G-band composite peak comprising peaks in the vicinity of 1600 cm⁻¹, and 1580 cm⁻¹, respectively, and at least one peak in the vicinity of the D-band at 1380 cm⁻¹, in Raman spectroscopic analysis using argon laser Raman scattering light at a wavelength of 514.5 nm, the interlayer distance of the lattice plane d₀₀₂, obtained by wide-range X-ray diffraction, being in the range of 0.335 to 0.337 nm, and is of a multi-layer structure, so that the mixture has both high-capacity characteristics and high-output characteristics as a negative electrode active material for a lithium ion secondary battery, and is most suitable for use in HEV. 

1. A negative electrode active material for a lithium ion secondary battery, comprising: graphite particle (A), each being substantially spherical in shape, and having fine protrusions on the surface thereof, wherein the graphite particles are obtained by impregnating, and coating a matrix of natural graphite, rendered spherical in shape, with a mixture of pitch and carbon black, followed by baking in a range of 900 to 1500° C.
 2. A negative electrode active material for a lithium ion secondary battery, comprising graphite particles (B), each being substantially spherical in shape, and having fine protrusions on the surface thereof, obtained by further graphitizing the graphite particles according to claim 1 at a high temperature.
 3. A negative electrode active material for a lithium ion secondary battery, comprising graphite particles, each being substantially spherical in shape, and having fine protrusions on the surface thereof, wherein the graphite particles are a mixture of the graphite particles (A), each being substantially spherical in shape, and having fine protrusions on the surface thereof, wherein the graphite particles are obtained by impregnating, and coating a matrix of natural graphite, rendered spherical in shape, with a mixture of pitch and carbon black, followed by baking in a range of 900 to 1500° C., and the graphite particles (B) according to claim
 2. 4. The negative electrode active material for the lithium ion secondary battery, according to claim 3, wherein the mixture of the graphite particles (A), and the graphite particles (B) is produced at a mixing ratio (by weight) of the graphite particles (A)=50 to 100%, the graphite particles (B)=0 to 50%, and (A)+(B)=100%.
 5. The negative electrode active material for the lithium secondary battery, according to claim 3, wherein the mixture of the graphite particles (A), and the graphite particles (B) is produced at a mixing ratio (by weight) of the graphite particles (A)=0 to 30%, the graphite particles (B)=70 to 100%, and (A)+(B)=100%.
 6. A negative electrode active material for a lithium ion secondary battery, comprising a mixture of the graphite particles (A) according to claim 1, and carbonaceous particles (C) obtained by baking a mixture of pitch and carbon black in a range of 900 to 1500° C. before pulverization and sizing.
 7. The negative electrode active material for the lithium ion secondary battery, according to claim 1, having a G-band composite peak comprising peaks in the vicinity of 1600 cm⁻¹, and 1580 cm⁻¹, respectively, and at least one peak in the vicinity of a D-band at 1380 cm⁻¹, in Raman spectroscopic analysis using argon laser Raman scattering light at a wavelength of 514.5 nm, an interlayer distance of a lattice plane d₀₀₂, obtained by wide-range X-ray diffraction, being in a range of 0.335 to 0.337 nm.
 8. A negative electrode fabricated by applying the negative electrode active material for the lithium ion secondary battery, according to claim 1, kneaded with an organic binder, to a current collector made of metal to be subsequently dried and pressed.
 9. The negative electrode according to claim 8, wherein a coating thickness in a range of 30 to 100 μm, and electrode density is in a range of 0.9 to 1.8 g/cm³.
 10. A method for producing a negative electrode active material for a lithium ion secondary battery, comprised of graphite particles, each being substantially spherical in shape, said method comprising the steps of: preparing a matrix of natural graphite, rendered spherical in shape; and impregnating, and coating the matrix with a mixture of pitch and carbon black, followed by baking in a range of 900 to 1500° C.
 11. A method for producing a negative electrode active material for a lithium ion secondary battery, comprised of graphite particles, each being substantially spherical in shape, and having fine protrusions on the surface thereof, said method comprising the step of further baking the graphite particles produced by the method according to claim 10 at a high temperature to be subsequently graphitized.
 12. A method for producing a negative electrode active material for a lithium ion secondary battery, said method comprising the step of mixing the graphite particles produced by the method according to claim 10 with carbonaceous particles obtained by baking a mixture of pitch and carbon black in a range of 900 to 1500° C. before pulverization and sizing. 